Vortech Engineering Automobile Parts 4fd020 010 User Manual

®
ENGINEERING, LLC  
1650 PACIFIC AVENUE • CHANNEL ISLANDS, CA 93033-9901 • (805) 247-0226  
P/N: 4FD020-010  
©2001 Vortech Engineering, LLC  
All Rights Reserved, Intl. Copr. Secured  
31JUL01 V1.1(Explorer/Ranger(4FD V1.1))  
Table Of Contents  
FOREWORD ...................................................................................................................... ii  
TABLE OF CONTENTS ..................................................................................................... iii  
TOOL & SUPPLY REQUIREMENTS.................................................................................. iv  
NOTICE .............................................................................................................................. v  
PARTS LIST ....................................................................................................................... vi  
1.  
PREPARATION/COMPONENT REMOVAL............................................................ 1  
OIL FEED LINE INSTALLATION ............................................................................ 1  
OIL DRAIN FITTING............................................................................................... 2  
MOUNTING BRACKET INSTALLATION ................................................................ 4  
FMU INSTALLATION.............................................................................................. 5  
FUEL PUMP ........................................................................................................... 6  
SUPERCHARGER INSTALLATION ....................................................................... 7  
SUPERCHARGER DRIVE BELT ........................................................................... 7  
AIR INLET DUCT ................................................................................................... 8  
SUPERCHARGER DISCHARGE DUCT ................................................................ 9  
FINAL REASSEMBLY & CHECK ........................................................................... 11  
2.  
3.  
4.  
5.  
6.  
7.  
8.  
9.  
10.  
11.  
P/N: 4FD020-010  
©2001 Vortech Engineering, LLC  
All Rights Reserved, Intl. Copr. Secured  
31JUL01 V1.1(Explorer/Ranger(4FD V1.1))  
iii  
4.0L EFXOPRLDO1R99E1R-1/9R9A4 NGER  
Installation Instructions  
Also applicable for the 1990-94 Mazda Navajo and 1994 Mazda B4000  
50 State Smog Legal, as per CARB EO #D-213-17  
Congratulations on selecting the best performing and best backed automotive  
supercharger available today... the VORTECH® V-2® Supercharger!  
NOTE: This supercharger kit is designed to fit on Ford Explorer/Mazda Navajo vehicles. This kit, with the  
addition of the Ranger Supplement assembly part number 4FD248-050, may be installed on 1990-1994 Ford  
Ranger and 1994 Mazda B4000 vehicles.  
Before beginning this installation, please read through this entire instruction booklet and the Street  
Supercharger System Owner's Manual which includes the Limited Warranty Program and the Warranty  
Registration form and return envelope.  
Vortechsuperchargersystemsareperformanceimprovingdevices. Inmostcases, increasesintorqueof30-35%  
and horsepower of 35-45% can be expected with the boost levels specified by Vortech Engineering. This product  
is intended for use on healthy, well maintained engines. Installation on a worn-out or damaged engine is not  
recommended and may result in failure of the engine as well as the supercharger.  
Vortech Engineering is not responsible for engine damage.  
Installation on new vehicles will not harm or adversely affect the break-in period so long as factory break-in  
procedures are followed.  
For best performance and continued durability, please take note of the following key points:  
1. Use only premium grade fuel 92 octane or higher (R+M/2).  
2. The engine must have stock compression ratio.  
3. If the engine has been modified in any way, check with Vortech prior to using this product.  
4. Always listen for any sign of detonation (pinging) and discontinue hard use (no boost) until problem is  
resolved.  
5. Perform an oil and filter change upon completion of this installation and prior to test driving your vehicle.  
Thereafter, always use a high grade SF rated engine oil or a high quality synthetic, and change the oil and  
filter every 3,000 miles or less. Never attempt to extend the oil change interval beyond 3,000 miles,  
regardless of oil manufacturer's claims, as potential damage to the supercharger may result.  
6. Before beginning installation, replace all spark plugs that are older than 1 year or 10,000 miles with original  
heat range plugs as specified by the manufacturer and reset timing to factory specifications (follow the  
procedures indicated within the factory repair manual and/or as indicated on the factory underhood  
emissions tag). Do not use platinum spark plugs unless they are original equipment. Change spark  
plugs every 15,000 miles and spark plug wires every 50,000 miles or earlier.  
TOOL & SUPPLY REQUIREMENTS  
Ford style Snap Lock fuel disconnect tool  
Factory Repair Manual  
3/8" socket and drive set: SAE & metric  
Flat #2 screwdriver  
Phillips #2 screwdriver  
Large screwdriver or pry bar  
Adjustable wrench  
3/32" drill bit  
Drill motor  
Center punch  
11/16" Greenlee™ Punch  
Silicone sealer  
Open end wrenches:  
3/8", 7/16", 9/16", 5/8", 3/4", 7/8  
Note: If your vehicle has in excess of 10,000 miles since its last spark plug change, then you may need:  
Spark plug socket  
6 new OE heat range spark plugs  
P/N: 4FD020-010  
©2001 Vortech Engineering, LLC  
All Rights Reserved, Intl. Copr. Secured  
31JUL01 V1.1(Explorer/Ranger(4FD V1.1))  
iv  
NOTICE  
This product is protected by state common law, copyright and/or patent. All legal  
rights therein are reserved. The design, layout, dimensions, geometry, and  
engineering features shown in this product are the exclusive property of Vortech  
Engineering, LLC. This product may not be copied or duplicated in whole or part,  
abstractly or fundamentally, intentionally or fortuitously, nor shall any design,  
dimension, or other information be incorporated into any product or apparatus  
without prior written consent of Vortech Engineering, LLC.  
P/N: 4FD020-010  
©2001 Vortech Engineering, LLC  
All Rights Reserved, Intl. Copr. Secured  
31JUL01 V1.1(Explorer/Ranger(4FD V1.1))  
v
1991-1994 EXPLORER/RANGER  
Part No. 4FD218-050SQ  
®
ENGINEERING, LLC  
PARTS LIST  
IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any short-  
ages or damaged parts immediately.  
Part Number  
2E228-020  
Description  
Quantity  
1
Part Number  
Description  
Quantity  
V-2 SUPERCHARGER ASSEMBLY  
4FD130-026  
7U030-016  
7P125-103  
7P250-066  
7P525-067  
7P250-082  
7P250-034  
OIL FEED ASSEMBLY  
1/4" oil feed x 23"  
-4 x 45° 1/8" NPT male elbow  
#4 swivel x 1/4" hoses, barb fit  
.500 crimp ferrules  
1
1
1
2
2
1
1
4FD111-021 MOUNTING BRACKET ASSEMBLY  
1
1
1
1
1
2
4
5
9
3
4
1
4
1
3
13  
1
4FD011-021  
4FD110-043  
4FD010-063  
4FD015-136  
7U250-020  
7A375-124  
7A375-100  
7A375-075  
7F375-016  
7L312-000  
7A375-325  
7C080-050  
7C010-035  
7L375-075  
7K375-040  
4FD010-034  
Mounting bracket  
Welded bracket assembly  
Bracket C  
1/4" NPT x -4 90° fitting  
1/4" NPT x 1/4" NPT straight tee  
Support brace  
11mm dowels  
3/8-16 x 1-1/4" bolts  
3/8-16 x 1" bolts  
3/8-16 x 3/4" bolts  
3/8-16 nuts  
5/16 - split (lock) washers  
3/8-16 x 3-1/4" bolts  
8mm x 1.5 x 150 bolts  
M10-1.5 x 35mm bolt  
3/8" lock washers  
3/8" AN flat washers  
Mounting plate  
4FD130-036  
7P375-042  
7P500-020  
7P500-002  
7P375-017  
7P375-045  
7P100-121  
7R001-008  
7U030-036  
OIL DRAIN ASSEMBLY  
Male connector, inverted flair  
Tube nut, inverted flair  
1/2" x 8" aluminum tube  
3/8" NPT x 1/2" straight hose barb  
3/8" NPT 45° street elbow  
Sealing nut  
1
1
1
1
1
1
1
2
1
#8 stainless hose clamps  
1/2" x 5" oil drain hose  
4FD238-068 FUEL MANAGEMENT UNIT (WITH LINES) 1  
4FD112-010  
4FD012-010  
4FD012-020  
4FD012-030  
7R005-001  
7S300-000  
7R002-052  
7S300-300  
7S300-200  
4FD050-010  
4FD015-020  
4FD015-010  
7F250-040  
7A250-175  
7R002-048  
7C060-010  
7F006-093  
7C080-023  
7R002-044  
7S275-200  
4FD012-040  
4FD012-050  
4FD012-060  
7S250-200  
7R002-040  
AIR PASSAGE ASSEMBLY  
Inlet duct A  
Intake tube A  
Intake tube B  
208-91 3.75" T-bone clamp  
3" 90° rubber elbow  
#52 hose clamps  
1
1
1
1
1
1
2
1
2
1
1
1
2
2
6
1
1
1
4
2
1
1
1
3
6
6Z110-111  
4FD145-156  
4FD146-166  
7U030-046  
7U100-055  
7E010-046  
12:1 black fuel management unit  
Fuel line assembly, male  
Fuel line assembly, female  
5/32" x 32" vacuum line  
6" nylon tie wraps  
1
1
1
1
7
2
#8 x 3/4" sheet metal screws  
3" x 3" sleeve  
3" x 2" sleeves  
Air plenum  
4FD113-010  
7U400-001  
7P250-126  
7P250-125  
7U030-030  
CHECK VALVE ASSEMBLY  
One-way valve  
1
1
1
1
1
Dual pipe bracket, adjustable  
Dual pipe bracket, fixed  
1/4-20 nut plates, clip on  
1/4-20 x 1-3/4" bolts  
#48 hose clamps  
6mm x 1.0 x 16 flat allen  
6mm nylock nut  
1/4" restrictor  
1/4" tee  
1/4" x 12" vacuum line  
4FD101-002  
8F001-002  
7R003-024  
7R001-004  
7P500-014  
7P312-003  
7U100-055  
5W001-011  
5W001-010  
5W001-002  
5W018-021  
7J010-001  
7F010-032  
5W018-036  
7U031-018  
7U030-010  
7C011-075  
FUEL PUMP ASSEMBLY  
155 inline fuel pump  
1-1/2" adel clamp  
1
1
1
5
1
1
8
1
3
1
1
2
1
1
1
1
1
8mm x 1.25 x 20 flat allen  
#44 hose clamps  
#4 hose clamps  
Ford fuel fitting adapter  
5/16" female fuel connector  
6" nylon tie wraps  
16-14GA eyelet  
16-14GA female slides, insulated  
Fuse tap  
2-3/4" x 2" sleeves  
Discharge tube A  
Discharge tube B  
Discharge tube C  
2-1/2" x 2" sleeves  
#40 stainless hose clamps  
18GA standard black wire  
#10 flat washers  
2A046-103  
BELT  
1
10-32 nylock nut  
18GA standard red wire  
5/16" x 20" fuel hose  
12mm x 20" fuel hose  
10/32" x 3/4" bolt  
P/N: 4FD020-010  
©2001 Vortech Engineering, LLC  
All Rights Reserved, Intl. Copr. Secured  
31JUL01 V1.1(Explorer/Ranger(4FD V1.1))  
vi  
1.  
PREPARATION/COMPONENT REMOVAL  
A. Disconnect the battery.  
B. Remove the air intake duct and valve cover  
breather hose.  
C. Remove the accessory drive belt.  
D. Rotate the vacuum reservoir located on top of  
the air conditioning condenser 180° (see Fig.  
1-a), rerouting the vacuum line attached to the  
mounting tab.  
E. Removetheairconditioningcompressor,butdo  
not break open any lines. Disconnect the air  
conditioning line bracket located in front of the  
water pump. Remove the air conditioning clutch  
electrical connector. Temporarily secure the  
compressor on top of the radiator shroud to  
provide work area.  
Fig. 1-a  
2. OIL FEED LINE INSTALLATION  
A. Remove the oil pressure sender (located near  
the power steering pump).  
B. Thread the 1/4" NPT street TEE into the oil  
pressuresenderextensionintheblock.Position  
the tee so that the branch portion faces forward.  
C. Thread the 1/4" NPT x #4 flare 90° fitting into the  
upper branch so that the flare end points up  
toward the brake master cylinder.  
D. Thread the original pressure sender into the  
center branch and reconnect sender wire.  
THREAD INTO OIL  
SENDING UNIT  
FITTING LOCATED  
IN BLOCK NEAR  
POWER STEERING  
PUMP  
NOTE: Keep all oil fittings and hoses abso-  
lutely clean. Use Teflon paste SPAR-  
INGLY ON THE MALE PIPE  
THREADS ONLY. NEVER use Teflon  
tape. Apply ONLY MOTOR OIL TO  
FLARE FITTINGS. NEVER OVER-  
TIGHTEN FITTINGS.  
Fig. 2-a  
E. Install the Vortech supplied oil line onto the flare  
fitting. Cover the loose end with a plastic bag for  
later assembly.  
P/N: 4FD020-010  
©2001 Vortech Engineering, LLC  
All Rights Reserved, Intl. Copr. Secured  
31JUL01 V1.1(Explorer/Ranger(4FD V1.1))  
1
3. OIL DRAIN FITTING  
A. Remove the two vacuum lines on the EGR  
reference module and mark their position for  
reinstallation. Remove module and bracket.  
B. Remove EGR reference module from mount.  
Bend the mount down lengthwise so that the  
module will run perpendicular to the ground to  
accommodate the discharge tube. (See Fig.  
3-a.)  
C. Remove the EGR tube coming from the ex-  
haust. Disconnect the EGR guard, vacuum line  
andelectricalconnector.RemovetheEGRvalve  
and assembly and set aside for reinstallation  
later. Remove the guard/bracket. Cut off and  
discard the upper portion of the bracket in the  
area shown in Fig 3-b.  
Fig. 3-a  
DISCARD THIS  
PORTION  
CUT HERE  
D. Remove the breather line connecting the intake  
to the vapor canister (located on the left fender  
apron) for clearance. Remove three left side  
spark plug wires from the spark plugs and the  
PCV valve and line for access to the left valve  
cover.  
E. Remove the EGR tube from the exhaust mani-  
fold.  
F. Remove the left valve cover using care to save  
the gasket.  
G. An 11/16" hole must be punched or drilled.  
Measure and mark the hole location following  
the graphic on the next page.  
H. Make an 11/16" diameter hole at the mark using  
a drill or chassis punch. Deburr the hole com-  
pletely. Thoroughly clean the valve cover. (See  
Fig. 3-c.)  
Fig. 3-b  
I. Installthe1/2"hosefittingintothe3/8"NPTx45°  
elbow and tighten.  
J. Insert the elbow fitting through the hole in the  
valve cover so the barb points forward and  
slightly up from horizontal. Secure with the  
sealing nut provided in the kit. Make sure to  
place the sealing side of the nut against the  
valve cover surface.  
11/16" HOLE  
K. Reinstall the valve cover. (See Fig. 3-d.)  
Fig. 3-c  
L. Install the 1/2" oil drain hose piece and #8  
clamps to drain fitting on valve cover.  
M. Reinstall the PCV valve and spark plug wires.  
Check and reposition any existing lines around  
the area.  
OIL DRAIN FITTING  
Fig. 3-d  
P/N: 4FD020-010  
©2001 Vortech Engineering, LLC  
All Rights Reserved, Intl. Copr. Secured  
31JUL01 V1.1(Explorer/Ranger(4FD V1.1))  
2
3. OIL DRAIN GRAPHIC  
Fig. 3-e  
P/N: 4FD020-010  
©2001 Vortech Engineering, LLC  
All Rights Reserved, Intl. Copr. Secured  
31JUL01 V1.1(Explorer/Ranger(4FD V1.1))  
3
4. MOUNTING BRACKET INSTALLATION  
A. With the air conditioning compressor tempo-  
rarily moved off to one side, install the two  
Vortech supplied 11mm dowel sleeves into the  
air conditioning compressor mount. (See Fig.  
4-a.)  
B. Position the spacer and bracket on the air con-  
ditioning compressor mount as shown. (See  
Fig. 4-b.)  
11mm  
DOWELS  
C. Remove the factory dowel sleeves from the  
bottom of the air conditioning compressor and  
setaside.Installthecompressorontopoftheair  
conditioning mount and brackets.  
Fig. 4-a  
D. InstallthefactorydowelsleevesintotheVortech  
aluminumadapterbracketandinstallthebracket  
on top of the air conditioning compressor. Insert  
the four supplied 8mm x 150mm bolts and AN  
washers. Start all bolts before tightening in a  
crisscross sequence. Make sure all dowels and  
brackets are aligned properly. (See Fig. 4-c.)  
SPACER  
BRACKET  
E. Using the supplied tie wraps, resecure the left  
side air conditioning line to prevent contact with  
the power steering pump or brake lines.  
FORWARD  
F. Install the supercharger mounting plate using  
four3/8-16x1"bolts,fourANwashers,two3/8"-  
16 nuts and two 3/8" lock washers.  
G. Reroute and install air conditioning clutch wiring  
connector. (See Fig. 4-d.)  
11mm  
DOWELS  
NOTE: If your vehicle has gone over 10,000  
miles since its last spark plug change,  
you will need to change the spark plugs  
now before test driving the vehicle.  
Fig. 4-b  
Fig. 4-c  
Fig. 4-d  
P/N: 4FD020-010  
©2001 Vortech Engineering, LLC  
All Rights Reserved, Intl. Copr. Secured  
31JUL01 V1.1(Explorer/Ranger(4FD V1.1))  
4
5.  
FMU INSTALLATION  
CONNECT TO MANIFOLD  
VACUUM/PRESSURE  
A. Locate the return fuel line spring lock connector  
(left side frame below master cylinder). Sepa-  
rate the return line with a spring lock disconnect  
tool. Snap the Vortech fuel line with the male  
spring lock connector into the fuel rail outlet.  
Attach the other end to the Vortech fuel man-  
agement unit inlet.  
B. Snapthesecondlinewiththefemalespringlock  
connectorontothefuelreturnlinethatreturnsto  
the tank (see Fig. 5-a.) Connect the other end to  
the FMU outlet at the center fitting. (See Fig.  
5-b.)  
INLET  
(FUEL LINE  
FROM  
STOCK  
OUTLET  
(FUEL FROM  
HERE  
RETURNS  
TO TANK)  
REGULATOR)  
Fig. 5-a  
EXPLORER/MAZDA NAVAJO FMU:  
1. Remove windshield washer fluid/cool-  
ant overflow reservoir by removing the  
twomountingboltsontheleftsidefender  
apron, disconnecting the fluid lines and  
wiring connection.  
FUEL  
MANAGEMENT  
UNIT (FMU)  
2. Mount the FMU behind the gas vapor  
canister bracket on the driver's side  
(FMU lines should be attached to the  
unit before it is mounted) using the  
sheet metal screws supplied in the kit.  
ENGINE  
3. Connectthe5/32"vacuumlinefromthe  
FMU to the intake manifold vacuum  
tree (located at the top rear of the upper  
intake manifold) and secure. (See Fig.  
5-c.)  
VORTECH  
FUEL PUMP  
FILTER  
FUEL  
PUMP  
RANGER/MAZDA B4000 FMU:  
FUEL TANK  
1. Mount the FMU on the left side fender  
apron,forwardofthestarterrelay(FMU  
lines should be attached to the unit  
before it is mounted), using the sheet  
metal screws supplied in the kit.  
Fig. 5-b  
2. Connectthe5/32"vacuumlinefromthe  
FMU to the intake manifold vacuum  
tree (located at the top rear of the upper  
intake manifold) and secure. (See Fig.  
5-c.)  
VACUUM  
TREE  
MANIFOLD  
NOTE: Make sure you have routed all fuel  
lines away from all moving parts,  
sharp edges, exhaust pipes and  
manifolds. Secure the fuel lines  
with the tie wraps provided.  
TOP VIEW  
Fig. 5-c  
P/N: 4FD020-010  
©2001 Vortech Engineering, LLC  
All Rights Reserved, Intl. Copr. Secured  
31JUL01 V1.1(Explorer/Ranger(4FD V1.1))  
5
6. FUEL PUMP  
A. Release any pressure from the fuel tank by  
momentarily loosening the filler cap.  
B. Disconnect the line to the fuel filter by carefully  
removing the white retaining tab. Attach the line  
to the adapter fitting as shown.  
C. Mount the fuel pump on the frame near the filter  
using the supplied #10 nut and bolt.  
D. Connect the fuel pump inlet to the adapter with  
the 3/8" hose provided.  
E. Connect the fuel pump outlet to the filter inlet  
with the 5/16" hose. Use the supplied Ford fuel  
connector and hose clamp.  
NOTE: Make sure that the hoses are routed  
smoothly with no kinks or sharp bends  
and away from sharp objects.  
F. Attach the negative pump terminal to a clean  
ground fastener with the wire provided.  
G. Connect positive terminal on fuel pump to fuse  
box (30 amp A/C works well).  
H. Secure the fuel pump and hose with the clamps  
provided.  
I. After installation is complete, start engine and  
check system for leakage.  
VORTECH FUEL PUMP  
GROUND (-)  
3/8" FUEL LINE  
FUSE BOX (+)  
5/16" HOSE  
STOCK  
FUEL FILTER  
TO  
RAIL  
EXISTING FEED LINE  
FROM TANK  
ADAPTER FITTING  
Fig. 6-a  
P/N: 4FD020-010  
©2001 Vortech Engineering, LLC  
All Rights Reserved, Intl. Copr. Secured  
31JUL01 V1.1(Explorer/Ranger(4FD V1.1))  
6
7. SUPERCHARGER INSTALLATION  
A. Reinstall the EGR valve by connecting the ex-  
haustmanifoldtubefirst, thenthevalve. Tighten  
all the fittings, EGR bolts and connect all the  
vacuum lines.  
B. Reinstall the modified EGR guard. Reconnect  
all wires and vacuum lines.  
C. Mount the modified EGR reference module.  
Reconnect all wires and hoses.  
D. Mount the supercharger mounting brace from  
the back of the mounting plate to the cylinder  
headusingthesupplied10mmx1.5bolt, 3/8-16  
x 3-1/4" bolt, 3/8 x 16 nut and 3/8" lock washers.  
(See Fig. 7-a.)  
E. Align the drain tube according to Fig. 7-b.)  
F. Mount the supercharger by guiding the drain  
tube into the 1/2" drain hose on the valve cover.  
Secure the drain hose with the hose clamp.  
Fasten the supercharger to the mounting plate  
with the five 3/8-16 x 3/4" bolts and AN type  
washers provided.  
G. Install the 45° flare to the 1/8" pipe fitting into the  
oil feed on the supercharger and "clock" it to the  
4 or 5 o'clock position.  
H. Attach the oil feed line and secure away from all  
moving parts and the exhaust manifold with tie  
wraps.  
Fig. 7-a  
I. On Explorer/Navajo applications, reinstall the  
washer/coolant tank and the necessary plumb-  
ing and wiring connections.  
Fig. 7-b  
8. SUPERCHARGER DRIVE BELT  
A. The new longer accessory drive belt is routed  
the same as the original belt except for accom-  
modation of the supercharger and idler pulleys.  
B. Route the belt around the outside of the super-  
charger drive pulley then around the inside of  
the idler pulleys as shown in Fig. 8-a).  
Fig. 8-a  
P/N: 4FD020-010  
©2001 Vortech Engineering, LLC  
All Rights Reserved, Intl. Copr. Secured  
31JUL01 V1.1(Explorer/Ranger(4FD V1.1))  
7
9. AIR INLET DUCT  
A. Rotate the vacuum tree located on the rear left  
side of the intake manifold approximately 180°  
to gain clearance for the intake/discharge ple-  
num. (See Fig. 9-c.)  
B. On automatic transmission equipped applica-  
tions, the transmission vacuum line must be  
removedfromthemanifold,reroutedandformed  
to run along the firewall for plenum clearance.  
The rubber portion of the transmission vacuum  
line must be cut and the Vortech supplied  
restrictorandcheckvalveassemblysplicedinto  
the two cut ends. (See Fig. 9-a.)  
C. Remove the plastic throttle cable retaining clip  
from the top of the intake manifold.  
D. Attach the two 1/4-20 nut plates to each of the  
suppliedsteelplenummountingtabs.Mountthe  
plenum mounting tab assemblies to the upper  
intake manifold. The thin, non-slotted tab is  
mounted to the upper manifold boss that is  
located near the idle-air motor using the sup-  
plied 6mm flat head screw. At the top rear of the  
upper intake manifold, install the thick, slotted  
tabwiththe8mmflatheadscrew.(SeeFig.9-b.)  
Fig. 9-c  
8mm FLAT HEAD  
REAR MOUNT  
1/4-20 BOLT  
E. Position the plenum bosses over the adjustable  
tabs and secure with 1/4-20 bolts.  
F. Mount the plastic intake duct to the super-  
charger inlet with the 3-1/2" T-bolt clamp, leav-  
ing the clamp loose.  
SNAP-ON  
NUT PLATE  
G. Secure intake tube 'B' to the plenum and plastic  
intake duct using 3" x 2" and 3" x 3" blue silicone  
sleeves and #48 clamps as shown in Fig. 10-a  
on the page 10.  
6mm FLAT HEAD  
H. Position intake tube 'A', 3" x 2" silicone sleeve  
and #48 clamps onto the plenum. Mount the 3"  
90° rubber elbow and #52 clamps into the mass  
air flow housing and connect to the intake tube.  
Connect the crankcase breather hose to the  
barb on intake tube 'A'.  
SNAP-ON  
NUT PLATE  
FRONT MOUNT  
TO TRANSMISSION  
MODULATOR  
Fig. 9-b  
1/4" TEE  
TRANSMISSION  
VACUUM LINE  
RESTRICTOR  
TO VACUUM  
TREE  
ONE WAY  
VALVE  
Fig. 9-a  
P/N: 4FD020-010  
©2001 Vortech Engineering, LLC  
All Rights Reserved, Intl. Copr. Secured  
31JUL01 V1.1(Explorer/Ranger(4FD V1.1))  
8
10. SUPERCHARGER DISCHARGE DUCT  
A. Slide a 2-3/4" x 2" sleeve and two #44 clamps  
onto the supercharger discharge. Use a 2-1/2"  
x 2" sleeve with #40 clamps on the discharge  
plenum. Install discharge tube A. Refer to Fig.  
10-a on page 10.  
B. Mount discharge tubes B and C together using  
a 2-1/2" x 2" sleeve and #40 clamps. Slide a 2-  
3/4" sleeve onto the throttle body and a 2-1/2"  
sleeve onto the discharge plenum. Attach the  
discharge tube assembly to the plenum and  
throttle body using #40 and #44 clamps.  
C. Underhood lamp must be removed or relocated  
to provide adequate clearance for the super-  
charger.  
NOTE: Position the intake and discharge tubes  
as low as possible for hood clearance.  
Due to factory variations, on some mod-  
els modification to hood insulation may  
be necessary.  
P/N: 4FD020-010  
©2001 Vortech Engineering, LLC  
All Rights Reserved, Intl. Copr. Secured  
31JUL01 V1.1(Explorer/Ranger(4FD V1.1))  
9
10. SUPERCHARGER DISCHARGE DUCT  
PLASTIC  
INTAKE  
DUCT  
3" x 3"  
SLEEVE  
DISCHARGE  
TUBE 'A'  
INTAKE  
TUBE 'B'  
2-3/4" x 2"  
SLEEVE  
2-1/2" x 2"  
SLEEVE  
2-3/4" x 2"  
SLEEVE  
FRONT OF  
VEHICLE  
2-1/2" x 2"  
SLEEVE  
DISCHARGE  
TUBE 'C'  
2-1/2" x 2"  
SLEEVE  
INTAKE  
TUBE 'A'  
DISCHARGE  
TUBE 'B'  
VALVE COVER  
BREATHER  
HOSE BARB  
RUBBER  
ELBOW  
MAF  
SENSOR  
Fig. 10-a  
P/N: 4FD020-010  
©2001 Vortech Engineering, LLC  
All Rights Reserved, Intl. Copr. Secured  
31JUL01 V1.1(Explorer/Ranger(4FD V1.1))  
10  
11. FINAL REASSEMBLY & CHECK  
A. Reconnect the battery.  
B. Check all fittings, nuts, bolts and clamps for  
tightness. Pay particular attention to oil and fuel  
lines around moving parts, sharp edges and  
exhaust system parts. Make sure all wires and  
lines are properly secured with clamps or tie  
wraps.  
C. Check all fluid levels, making sure that your  
tank(s) is filled with 92 octane or higher fuel  
before commencing test drive.  
D. Start engine and allow to idle a few minutes,  
then shut off.  
E. Rechecktobesurethatnohoses,wires,etc.are  
near exhaust headers or moving parts and for  
signs of any fluid leakage. Check ignition timing  
to make sure it is set to stock specifications  
before commencing test drive.  
F. PLEASE TAKE SPECIAL NOTE: Operating  
the vehicle without all of the subassemblies  
completely and properly installed may cause  
FAILURE OF MAJOR ENGINE COMPO-  
NENTS.  
Fig. 11-a  
WARNING: Do not attempt to operate the  
vehicle until ALL components  
are installed andALL operations  
are completed including the fi-  
nal check.  
G. Test drive the vehicle.  
H. Read the STREET SUPERCHARGER SYS-  
TEM OWNER'S MANUAL AND WARRANTY  
REGISTRATION FORM within thirty (30) days  
of purchasing your supercharger system to  
qualify.  
P/N: 4FD020-010  
©2001 Vortech Engineering, LLC  
All Rights Reserved, Intl. Copr. Secured  
31JUL01 V1.1(Explorer/Ranger(4FD V1.1))  
11  
®
ENGINEERING, LLC  
1650 PACIFIC AVENUE • CHANNEL ISLANDS, CA 93033-9901 • (805) 247-0226  
P/N: 4FD020-010  
©2001 Vortech Engineering, LLC  
All Rights Reserved, Intl. Copr. Secured  
31JUL01 V1.1(Explorer/Ranger(4FD V1.1))  

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